Electric steam iron



J. O. THIBAULT ELECTRIC STEAM IRON Oct. 20, 1953 3 Sheets-Sheet.

Filed May 16, 1950 \5, Ii 1 A R 3nventor Oct. 20, 1953 Filed May 16,1950 J. 0. TH IBAU LT ELECTRIC STEAM IRON 3 Sheets-Sheet 2 (Jase 07? 0.Th (64a! (Ittomcgs Oct. 20, 1953 J. o. THIB'AULT 2,655,745

ELECTRIC STEAM IRON Filed May 16, 1950 5 Sheets-Sheet 3 Jase 7: 0 ThiauZz Gttornegs Patented Oct. 20, 1953 UNITED STATES ATENT OFFICE ELECTRICSTEAM IRON Application May 16, 1950, Serial No. 162,177

This invention relates to steam irons, particularly electric steam ironsof the type manufactured for domestic use, in the home.

Heretofore electric steam irons of the above type have generally adheredto a structural design characterized by the boiler, which was mountedabove the sole plate, also constituting the casing of the iron. Theseboiler-casings were either made as castings of aluminum or the like, oras composite sheet-metal structures employing welding, soldering orsimilar fastening means in their fabrication.

Presumably the purpose behind such prior designs was to obtain a largewater capacity, together with simplicity of construction and economy ofmanufacture.

One prior type of composite sheet-metal boiler construction consisted ofan upper section in the form of a dished drawn sheet-metal shell havingthe usual dome-like casing shape with a depending skirt engaging thesole plate, and a cooperable lower section comprising a bottom plateprovided along its edge portions with downturned or outturned flangesengaging the inner upright Walls of the skirt of the upper or casingsection. The engaging portions of the two sections, which were inoverlapping relation, were then seam-welded together. This proceduremarred the outside surfaces of the skirt of the casing section, andproduced a difiicult problem in the matter of finishing the casing. Thisproblem was aggravated by the fact that the casing sections were made ofstainless steel, which is particularly resistant to polishing andfinishing operations where pockets are formed and appreciable materialhas to be removed to provide smooth surfaces.

As a consequence, the matter of finishing the boiler-casing assembly wastime-consuming and expensive, and not conducive to quality finishing.Moreover, with this prior type of construction there was anothersignificant disadvantage in that the portions to be seam-welded did notlie in a single, flat plane, but instead followed a curved, devious pathnecessitating turning and twisting of the assembly during the welding.This was not only difiicult, time-consuming and costly, but oftenresulted in imperfect welds, causing leaky boilers in which the defectshad to be first located and then corrected. A further difliculty aroseif the boiler-casing developed defects after being put into service.Where such defects involved leakage, which was often the case, theboiler-casing assemblage would have to be removed and replaced by acomplete new 5 Claims. (01. 38-47) assemblage, which was usually done ata service or field station. This caused quite appreciable expense to thecustomer, since the replacement did not involve simply a boiler butinstead also involved a highly finished casing part, produced atrelatively great cost due not only to its being made of stainless steelbut also because the welding formed pockets in the outer surface, whichhad to be removed by the finishing process.

In another prior type of iron a composite stainless steel combinedcasing and boiler was formed of an upper section comprising adome-shaped shell constituting the casing and a cooperable lower sectioncomprising a bottom and back plate, which had upturned and inturnedflanges around its edge portions, engaging the innerand undersurfaces ofthe top section. In this particular prior art construction silver solderwas used to join together the two sections. While this eliminated thepitting of the outer surfaces of the upper or casing section, it was notparticularly well adapted to simple and rapid, economical production anddid not completely remedy the leakage problem (requiring subsequentcorrecting operations), nor the high cost of finishing a stainless steelcasing part, nor the high cost of replacement if the casing-boilerassembly developed defects after being put into use.

The present invention overcomes the difliculties and disadvantages ofthese prior constructions mentioned above, it being an object of theinvention to provide an improved electric steam iron of exceptionalquality and sturdy and rugged construction, characterized by reliableperformance and large water capacity while at the same time being simpleto construct and manufacture, and easy and economical to service.

In accomplishing this object I have departed from the usual and acceptedprocedure followed in the past, of making the boiler and easing as asingle unit. Instead, I make the boiler and casing as separate units,the boiler being formed of sheet-metal sections secured together, andthe casing of a separate dome-shaped sheet-metal shell adapted tooverlie and surround the boiler. I have found that by so doing, contraryto expectations, desirable economies in the finishing operations of thecasing and in the fabrication, particularly the welding, of the boilermay be effected. The welding, besides being quicker and less costly, ismore effective, thereby eliminating leaks and reprocessing and providinggreater reliability in boiler performance and life. In addition,servicing of the iron is made easier, and boiler replacement is lesscostly.

By the present invention, the construction and arrangement of the boilermay be worked out without regard to its finish and appearance, so thatthe factors of ease and reliability in the welding of the boilersections may be given the fullest consideration. The casing according tothe present invention may be separate from the boiler, and may, be. madeofa metal difierent from stainless--'steel or' other metals-which arediflicult to finish and are rust and corrosion reh The casing metal maybe chosen for:

sistant. its ease and economy in forming and-finishing. I have found itadvantageous to form the boiler of upper and lower,facing,zdishedssections,.each; section comprising a sheetemeta lgshellhaving ae rim including an outturned flange disposed" in a single, fiatplane. circumferential overlapping portions, and'are se cured togetherin water-tight relation-.toform;

Thus there may be employed a quick a vessel. and economical;continuousseam-welding procedure, whichxmay; be. doneon semiautomaticequipment, prod ueinga highly, efl'icient; seam. or. joint which. iscompletely water-tight and. also reliable-in use even. though subjected;to stresses imposed bythe manipulating. ofithe iron.-

I' have' found that. the welded joint formed by, the outturned.fiangestwhich: are. disposed in flat planes, overlapping each other, isso sturdy;

and rugged that,advantagemay.betakenof this manufacture. of. the. iron;but when. it. becomes.

necessary to dismantle itheirontdcarry, out servicingoperations.

By making the. casing and boiler, separate and. distinct-from each.other, notnnly can. the .casing; be economically finished becauseit.can be. made. of metal. difierentfrom. the rusteproofmetal. of

theboiler, .but .in-the..event..that.at. a .later. date the boiler showssomedefect and; requires re placement, the cost of such.replacementwillbe relatively low because. it. does not. involve thediscarding. of. a. finishedv casing. as was. heretofore thev case.-.

Theinvention is embodiedin an. iron of the. type. having a. pivoted;handle, which can be swungback. from. operative. position to exposethefiller. openingfor. the. boiler, and in connec tion with thisorganization-L'dispose the fasteningmeans i'orthe..casing.so astobenormally concealed by thehandle, and to beexposed .when

the handle is swung. back to filling... position,.

thereby. simplifying. the dismantling of .theiron whenservicing isnecessary.

In order to. obtain. relatively large water capacity Itrim'the weldedoutturned fiangesof theboiler after. the welding thereof, to reduce the.width of. the flanges to.a relatively small.

figure. Accordingly'the side walls of the boiler maybe brought into.close proximity to the side walls. of. the-casing, reducing. the unused.space between the boiler. and; casing, and. enabling a' relatively largeboiler. capacity to. be obtained for a'given casing size: Moreover, .by.theprovision' of the aforesaidlspace between. the. boilerand"the;casing, that-latter functions:- as. an ef fective shield, being;maintained at a? relatively:

The flanges have continuous 4 cool temperature whereby it is not so hotto the touch and not so likely to cause burns or discomfort if a usershould inadvertently come in contact with the casing.

I utilize the welded flanges of the boiler as part of the means forsecuring the boiler to the casing, thereby providing an extremely simpleand. reliable mounting...

Other features-and advantages will hereinafter appear.

In the accompanying drawings:

EigureLis a vertical, longitudinal sectional view'ofan'electric steamiron embodying the invention:.

Fig'zzfis an enlarged fragmentary detail of the steamdome=and upperportions of the boiler and easing, illustrating. the means for fasteningthe casing to the boiler.

Fig.3 is an enlarged fragmentary detail of the filler opening of theboiler, showing the gasketetype-seali-ng. meansinterposed.betweentheboiler, and thecasing;v

Fig. 4 is a rearr elevational View of the iron, with. portions broken.away and. shownin. section to illustrate. interiondetails...

Fig. 5 isa top. view ofthecasingofthe iron.

Rig. 6-- is a. top View. of; the.- complete. sheetmetal boiler.

Fig. 7 is a side elevationalview of the boiler.

Fig. 8 isa top viewoftheboiler.afterassembly and. weldingof the-parts,but. prior: to trimming, off excess material, and:

Fig. 9..is aplan view=ofaheahconducting. shim such as is interposed..betWeen.the-.-sole. plate and.

. boiler, and between the sole plateandthermo:

stat.

The ironembodyingthe.invention as shown in Fig; 1, comprises -a.soleplate. lilhaving. anelectric heating element. .connectedwitli athermostatv [2. which. is vmounted on. the. rear portion. of the. sole.plate- The.-thermostat-. l2iisof. the usual .type, having a frame.ljiiImounting ,contacts. i4 and [5-, the latter contact .being.actuated. .by. alever. it engagedby. allow expansion. strip. l'il"which. is. securedlto a high. expansion, strip -v 18.

attached. toathe .fiame. I 3? Adjustmentof the thermostat I2 isprovidedf fonby aknob .liiicarriedjona shaftitiwhichengages.the...contact ieandis threaded'into alsleeve 2] 'carriedby theframe 131 Atthefrontof the .soleplate lil a' steam chamb.er..'22visprovidd, ,enclosediby a. cover plate 23 into, which there. is:threaded. an. upright steam tube. 25!. having .an.-extension 24a. ofreduced diameter. The. steam tubeZAhas notches. 25b in" its end, to.accommodate v a wrench.

In accordance with the invention a novel assemblage of sheet-.metalboiler and separate sheet-metall casing is provided, in conjunction.with the sole plate liljto produce a superior quality steam ironcharacterized by low manufacturingcost, high performance andreliability, ease..of disassembly and servicing, and'low-cost' boilerreplacement should thiseverbe necessary.

As shown in Figs. 1,. 6,,T'and 8, the boiler of this assemblage,indicated by the numeral 25, comprises a dished, upright, lowersheet-metal section 26' and a. dished; inverted, upp'er sheetmetalsection 21'. The sections. 26 and 21 are shaped. and formed by the.usual. punches and. dies and after leaving thetoolshavethe.con=figurations shown in Fig. 8, with irregular shaped, outturned flanges23. and 29. Inassernbly, the boiler sections. 26 and 27 are placed;together.

with. their flangesimengagement andisubjected;

to a seam-welding operation which joins the flanges together closelyadjacent the walls of the sections. After this, the assembled sectionsare placed in a trimming tool, and the excess material removed from theflanges, leaving the configurations shown in Figs. 6 and 7, includingapertured mounting ears or lugs 30.

Prior to the assembly of the boiler sections, the upper section 2'! isprovided with a filler opening 3| having a valve seat 32 dependingtherefrom. The valve seat 3| may be advantageously made of a drawnsheet-metal cup, and may have a crimped flange 33 and a, second flange34 between which the upper wall 35 of the boiler is securely gripped.

Also, prior to assembly of the boiler sections, the upper section 21 isprovided with a second opening 36 in its front upper portion, aroundwhich a hollow threaded boss 31 is secured. As will be seen in Fig. 1,the extension 24a of the steam tube 24 passes upwardly through the boss37 and projects above the top of the boiler 25. Between the openings 3!and 35 of the boiler a depressed portion 38 is provided, to provideclearance for a latching structure as shown in Fig. 1.

Enclosing the boiler 25 and secured to it is a dome-shaped casing 39 inthe form of an elongate shell, which is also drawn of sheet-metal. Thebottom edge or rim 40 of the shell engages the edge portions of the soleplate l0, being received in a peripheral recess 4| provided for thispurpose. The front upper portion of the casing 39 is provided with anopening 52 through which the boss 3'! of the boiler extends, and a steamdome 43 in the form of a drawn sheet-metal thimble is threaded onto theboss 3'! so as to enclose the upper portion of the steam tube extension24a and to securely fasten together the adjacent upper portions of theboiler 25 and casing 39. For this latter purpose, the steam dome it hasan outturned flange 44 engaging a washer 45 which surrounds the boss 31and rests on the casing 39.

Referring to Figs. 1, 4 and 6, the apertured lugs 36 of the boiler 25receive screws 45, which are threaded into upstanding bosses 41 on thesole plate I0, thus fastening the rear portion of the boiler to the soleplate.

The rear central part d8 of the casing 39 is depressed. It has adownward and backward slope-cl fiat portion 45, merging with ahorizontal edge portion 5|) which terminates in a transverse dependingflange 5|. The horizontal edge portion 5|) at its center extendsforwardly at 52 and is provided with a screw hole 53. A steep slopingwall 54 joins the portions 49 and 52 together. As seen in Fig. 1, ascrew 55 passes through the hole 53 and is threaded into a boss 56 onthe sole plate N for the purpose of securing the casing 39 to the soleplate. In order to steady the casing on the sole plate without employingadditional fastenings, two upright bosses 55a are provided on oppositesides of the boss 56 and spaced therefrom a substantial distance, thebosses 56c engaging the underside of the horizontal edge portion 55 ofthe casing. To provide clearance for the thermostat shaft 20, theportion 49 of the casing is provided with an aperture 51 substantiallylarger than the shaft.

In order to obtain a steady, smooth-acting bearing for the shaft 20 abearing bracket 58 is provided, in accordance with the invention, havingan opening 59 through which the shaft passes and against the walls ofwhich it bears. The bracket 58 has apertured ears 50 through'which 6.fastening screws 6| pass, said screws being threaded into the upper wallportion 48 of the casing.

The top of the casing 39 has a large central opening 62 which is alignedwith the filler opening 3| of the boiler. Around the edge of the opening62 a depending flange 63 is provided, and encircling the flange 53 is awasher or gasket 64, interposed between the top walls of the casing andboiler to provide a seal and prevent water from leaking between thecasing and boiler when the latter is being filled.

The casing 39 has at its rear a pair of inwardly facing walls 55 whichare apertured to receive spring loaded trunnion pins 65 carried in therear portion 67 of a handle structure 58. The handle structure 58 issimilar generally to that shown and described in my copendingapplication Serial No. 103,437, filed July 7, 1949, entitled SteamElectric Iron. It consists of a broad flat base plate 59 havingupstanding front and rear posts ill and H respectively which areconnected together at their tops by a handle proper 52. The rear post'H- has a recess 13 to accommodate the thermostat knob I9, and the frontpost H3 has a recess M to accommodate the steam dome i3.

As shown in Fig. 1, the handle structure 68 may be swung backward to afilling position indicated by the broken lines. When in this position itexposes the filler opening 3| of the boiler 25. On the underside of thebase 69 of the handle a valve 75 is mounted, for cooperation with thevalve seat 32 carried by the upper wall of the boiler 25.

To releasably lock the handle structure 68 in operative position a latch16 is provided.

For the purpose of reinforcing the top wall of the boi er 25 around thefiller opening 3| thereof, so as to minimize distortion of said wall bypressure imposed upon it by the closure 15, reinforcing ribs 11 areembossed in the boiler wall, Fig. 6. These ribs prevent the boiler walland easing wall from separating at the gasket 64, and maintain thegasket in tight sealing relation with the said walls.

It will be seen that by the above construction the handle structure 68is secured to the casing 39 at the rear by the trunnions 56, and to theforward portion of the casing by the releasable latch 15. The casing 39,in turn, is secured to the sole plate ID at the rear thereof by thesingle screw 55, and at the front is not fastened directly to the soleplate but instead to the top forward portion of the boiler 25 by meansof the steam dome 43.

I have found that, by making a composite boiler of sections havingoutturned flanges lying in substantially flat planes, and seam-weldingthe flanges together, an extremely strong and sturdy unitary structureresults which will not develop weakness or failure even with the handletransmitting force to the sole plate through the forward portion of theboiler. The casing 39 is nowhere at its forward portion secured directlytothe sole plate. Instead, it is secured to the upper portion of theboiler, and the lower forward portion of the boiler is secured to thesole plate by the steam pipe 24. Thus, as a consequence of effecting astrong weld between the boiler sections 25 and 21, I have obviated thenecessity of securing the casing 39 directly to the sole plate at thefront of the iron. Accordingly I have accomplished a simplification ofthe fastening means, resulting in a desirable economy in manufacture andassembly of the iron, and

simplifying-the dismantling ;of .theiron for service ing orreplacementzof.the.;boiler:

Moreover, by making the boiler 25 separate from thecasing 39;replacement-pf the boilermay berefieetedwithout-.requiringr replacementof the highly finishedi casingpart.39.- Thusetheacuse tomen in 1 theeventeoffailure .of the :boiler. need not. payfor. aefinished. casingpart, but 1 instead only-for. a boiler as such... Since-the boiler'doesnot have a highly finishedsu-rface which is ;ex-. pensive.- to: produce,its initial. cost is= relatively low and as a result replacement of-thezboiler'- does not involve an .appreciablyg high: expense-.

sinceethee boiler. 25;- and: the: casing, 3.91am

entirely separate.from. each: other, the.- material fonthe boilerrnay-;be.-chosen-from any of various rust? and corrosion-resistantmetals-ewithontregard;.-to-.-the. problem t finishing. and the -mate--rialsof the? casing -may bezchoserr primarily or largely. with regard,tothe finishing. Irraddition, since there is. no. welding. involved:inothe cone struction-ot. the casing; 39,-'.to.'cause= pockets ormarkings on the exterior. surface. thefinishing of the casingmay be donequicklyand economically.

Considering the: boiler. itself, the provision of the flatfianges. 28-.and .29.'enab1e. the. boiler secs tions-to. beseamewelded-together: atthe. flan e by semiautomaticeqnipment; anditis not reqniredrthattheboilerbetwisted or maneuvered along-an. intricate curvedpath during thewelding; operation. Accordingly the welding. maybe carried.- out quicklyand economically, and may be made --very effective. to. providecompletely watertight joints. at the. flanges.

By virtue oi. the flanges. 28.. and. 29-. being trimmedoff closeto..the.,side. walls. of the boiler 25 latter the welding theboiler.walls. and casing walls maybe brought.int0..cl0se.proximity, minimizing,the amount. of spacenot utilized. for water, between the boiler. and.casing wallsand resulting in. a relatively. large. boiler. capacity.Therelatively smalliair space. whichdoes exist between the walls ofthe..boil'er.-v and. the: casing. however, provides an effective heatinsulator. to prevent the. casing from .becomingashot as ,the walls ofthe boilen. Thusthelikelihood .of'aauser becoming burned'ifJheinadVertentIy touchesthe casing is considerably. reduced...

Because of the simplified welding procedure .by which the boiler of thisinventionmay be.fabri cated, together withthe. ease and rapidity of.fin.-. ishingthe casing surrounding the.boiler, I. have efiected a;desirable economy, in themanufacture of the iron. Contributing to thisalso. is the effectiveness of the weldin which. minimizes leakagedefects andlsubsequent corrective processing operations, and thesimplification of fastening means .by which the sole. plate, boiler andcasing, are secureditogether;

In-order toiprovide a more efiicient. heat trans+ fer from the soleplate I0 to the boiler 25 I provide, in'accordance with this-invention,fluted or ribbedshims 18, Figs: 1 and 9, which are inter-'- posedbetween-the bottom wall of theboilerandthe top walliof the-sole platealong the area-dis posed directly overthe heating element ll.

Referring torFig 4; animproved cord anchor age-isprovided -to;securelyfastenthe supply cord- 1 9: to .the-iron atthe point :where itpassesithrough; the wall of;th,e .casing 3.9. This-:cordanchoragecomprises. anexternally threaded hollow boss. or bushing Bil. whichismounted onthe casing 39,. said bushinghavingataperedbore 81. Theelectrier cord 19tpasses throughthe. bushingjfl. and

is..engag ed .and..grip pedl.by spring. fingers BZ. ex.-.-

tendinggiromzaafiatlwashen-likeebody ,83subjected toforceseexer-tedlbyea cap-84 threaded omthe bushing 8.0L,The.fingers.821areeforcedlongitudh nallydnwardaga-inst thetapered bore.8L of the bushing-whenthecap :.83.is tightened. thussforcs ingthe.fingers inward against. the. cord-19-to securely grimthelatter.

A ihelical ..wire,-cord- :protector. 85= is, .providedzon the. cord,- 19 one: 811G386 :of the: protector having anenlarged. diameterand-fitting within the cap 84.to beheld...theretdbyvaneinner. flange 81on theccap.

Variations. and; modifications: may be; made within.the scope .ot. the:claims portions. or the improvements may be used without others...

Lclaimr.

L In .a ,steam .iron,..a sole:plate;..a boiler. dis.- ppsed. above. thevsole. plate}. a: shell-like. casing having a .top. and depending. sides,enclosing. the boiler; removable. means en aging the. forward interior.bottom; portion ,ot. the boiler, releasably securing the -,forw ardbottom ortion .to the. sole plate; meanssreleasablyr securing. the rear.of. the boiler to. .the. sole, plate; means, independent ofboth,-.-said,preceding, means,. releasably. securing the rearotthecasingto the .sole'plate; and means releasably securing the. forward upper.ortions of-the boiler andcasing together, said casing: and boiler beingseparablefromthe.sole. plate. and from each. other whereby, replacementof, the boiler. may be readily effected.

2; ma steam iron...a.sole,plate;-a boiler dis: posed above. the-sole.plate;.a shell-like. casing having .a .top anddepending sidesenclosingthe boiler; removable means engaging the forward interior bottom.portion ..,of'.the. boiler, .releasably securingthe.forwardlbiottomlportion to .the. sole plate; means .r'elea'sablir.securing.,the rear, of the boiler. to the sole plate; means.independent. of both saidflpreceding means, .releasably. securing therear of. thecasing to. the sole p1ate;.and means releasably. securing.the. forward upper portions ofthe' boiler and casing together, saidcasing portion having an opening and said meansincluding;aibushingpassing through said open: ing and 'a" steam domeremovably attached .to the bushing and" projecting upwardly from thecasing, said-casing and 'boiler'beingseparable from thesole plate andfromeachiother whereby replacement of'th'e boiler may be readilyefiected.

3." The invention' as defined in claim 1, in which the means;forfastening; the rear of the casing tothesole plttteromprises solely acentrally; located screw passing through .a. top, wall ofthe casing" andthreaded into;the .sole plate, andlin which the? sole platehas means.engaging theun'dersurfaceoffthecasing top wall on opposite sides'ofsaidscrew, for steadyingthecasing,

4. In aisteam iron; asole plate; aboilermounted on the :soleplate; acasing enclosing the top and sides of the boiler; means releasablyfasten-v ing together the front upper portions of the boiler and casing,'means releasably fastening the: rear of the casingto thesole plate; ahandle disposed above the... casing; having means. overl'yingandconcealingjooth said fastening means; andmeanssecuringthe.handleinoperativeposittion. on the casing, saidhandlesecuring means being'manuall'y releasable to enablethe handle tobeshifted out of operative position to expose both saidfastening means:

5; .In asteam iron, a soleplate; a sheet-metal boiler secured. to thesole. plate;.. a .casing .come prisinga sheet-metal shell...enclosing,theboiler,

said. casing and; boiler having alignedi openin s 9 in superposed upperportions to enable the boiler to be filled; gasket means disposedbetween and sealing the edge portions of both the openings of the boilerand casing to prevent leakage of fluid therebetween, said casing havinga down-turned flange around the opening in its top portion, extendinginto said gasket means and positioning the same; and means remote fromsaid gasket means, securing the casing to the sole plate and maintainingthe gasket means under compression to preserve said seal.

JOSEPH O. THIBAULT'.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date Jones Nov. 26, 1940 Wiggins Feb. 20, 1940 Finlayson Sept. 8,1942 Riddington et a1. July 22, 1943 Morton Mar. 28, 1944 Ellinwood eta1 Oct. 24, 1950 FOREIGN PATENTS Country Date France Aug. 18, 1930France June 20, 1938

